Operating Instructions

for WABCO's
Diagnostic Controller
446 300 320 0
with
Program Card ABS/ATC C (SAE)
446 300 514 0

Edition: July 1996

Copyright WABCO 1996

WABCO
Fahrzeugbremsen
A Division of
WABCO Standard GmbH

TABLE OF CONTENTS

LIST OF ABBREVIATIONS USED:

Page

ABS

Anti-Lock Braking System

Diagnostic Controller Set . . . . . . . . . . . . 3

ATC

Automatic Traction Control

ECU

Electronic Control Unit

L1/L2

Wheels on steered axle

(diagonals 1/2)

A1/A2

Wheels on driven axle

(diagonals 1/2)

Z1/Z2

Wheels on third axle

(diagonals 1/2)

MRV

Modulator valve (ATC)

Diff.
valves

Differential brake valve (ATC)

IV

Inlet valve which when energized

prevents further pressure increase
at the wheel brake

OV

Outlet valve which when energized

allows pressure at the wheel brake
to be released

PIN

Individual connector in the ECU

plug

MOTvalve

Engine valve with on/off control for

ATC (also known as black / white
valve)

PROPvalve

Engine valve with proportional

control for ATC operation

>

greater than

Which Systems Can Be Tested? . . . . . . 4

Connecting the Diagnostic Controller . . 5
Operating the Diagnostic Controller . . . 5
Programme Structure . . . . . . . . . . . . . . . 6
1.
1.1
1.2
1.3
1.4
2.
4.
5.
6.

Diagnosis . . . . . . . . . . . . . . . . . . . 6
Error Memory . . . . . . . . . . . . . . . 6
Component Actuate . . . . . . . . . . 7
Measured Values . . . . . . . . . . . . 8
ECU Parameters . . . . . . . . . . . . . 8
System Check . . . . . . . . . . . . . . . 8
Multimeter . . . . . . . . . . . . . . . . . 10
Options . . . . . . . . . . . . . . . . . . . 10
Special Functions . . . . . . . . . . . 11

Example of Fault Search . . . . . . . . . . . 11

Functional Fault in Diagnostic System

13

Print-out of Test Results . . . . . . . . . . . . 16

Circuit Diagram
4-Channel ABS/ATC C . . . . . . . . . . . . 17
Circuit Diagram
6-Channel ABS/ATC C 6S/4M . . . . . . 18

<

less than

ohm

kilo ohm

wheel A Left Front

(LF)

wheel B Right Front

(RF)

wheel C Left Rear

(LR)

wheel D Right Rear

(RR)

DIAGNOSTIC CONTROLLER SET

446 300 331 0

Contents of Diagnostic Controller Set:

1. Diagnostic Controller

446 300 320 0

2. Carrying Case

446 300 022 2

Additional Test Equipment

3. SAE Connector Cable (DEUTSCH)
SAE Connector Cable (AMP)

894 604 350 0

894 604 351 0

4. Measuring-Adapter (35 pins)

446 300 314 0

5. Measuring-Adapter (54 pins)

446 300 309 0

6. Multimeter Cable (black)

Multimeter Cable (red)

894 604 301 2

894 604 302 2

7. Bridging Cable

894 604 300 2

8. Programme Card

446 300 514 0

WHICH SYSTEMS CAN BE TESTED?

This program card can be used to test certain ABS/ATC systems which are identified by the
part number of the ABS/ATC control unit.
ABS/ATC C-Generation (SAE)
system/plug

4-channel/35 poles

6-channel/54 poles

programm card

446 300 514 0

446 300 514 0

measuring adapter

446 300 314 0

446 300 309 0

446 300 325 0

446 300 330 0

446 004 038 0

039 0
040 0

446 003 038 0

application:
fault search

inter-adapter
application:
if no diagnostic
plug (to SAE J1587)
on vehicle

ECUs which can be

tested

CONNECTING THE DIAGNOSTIC

CONTROLLER
1a. Diagnostic socket to SAE J1587
available on vehicle
The allocation of PINs in the diagnostic socket
must correspond to the SAE J1587 standard
as shown below. Connect Diagnostic Cable to
diagnostic socket on vehicle.
Allocation of diagnostic socket:
PIN A diagnostic line (+)
PIN B diagnostic line ()
PIN C battery positive
PIN E battery negative

Controller, thus establishing both the diagnostic connection and voltage supply. Switch
on ignition. The display will show black bars
until a programme card is inserted. If an interadapter is used, the red toggle switch must be
in position 1 to establish a voltage supply to
the ECU.
3. Insert programme card, pushing it fully home
(contact side first, black surface facing upwards). The display will now show which card
has been inserted.

OPERATING THE DIAGNOSTIC

CONTROLLER

1b. No diagnostic socket to SAE J1587

available
If there is no diagnostic socket on the vehicle,
an interadapter (accessories) can be fitted
between the ECU and the vehicle harness
connector (see diagram).
4-Channel

The Controller is operated by means of three

push-buttons on its front panel. Their allocation is shown via the instructions appearing
on the display directly above the respective
push-button.
1 Diagnosis
4 Multimeter
2 System check
5 Options
3 Error acc. to J1587 6 Special function
Select function! EXIT
START

Push-button Function

6-Channel

2. Connect the 9-pin plug of the connector

cable (or the adapter cable) to the Diagnostic

START :
RETURN :

Initiate programme.
The display will return to the
last main menu.

(ARROW):

Select an item from the main

menu. Scroll forward one item
at the time by pressing the
push-button. The item selected
will blink.

CONTINUE: The item selected is activated

or released.
REPAIR
This command will activate the
failure search for the displayed
error. However, by pressing
CONTINUE you may display all
errors first.
5

PROGRAMME STRUCTURE
ABS/ATC C (SAE)
1 Diagnosis
1 error memory
2 component actuate
1 ABS warning lamp
2 ATC lamp
3 third brake
4 differential valves
5 ATC engine control
1 electronic engine interface
2 PROP-/MOT-Valve
6 modulator valves
1 modulator test cycle
2 set pulse time

1. DIAGNOSIS
1 Diagnosis
4 Multimeter
2 System check
5 Options
3 Error acc. to J1587 6 Special functions
Select function!
EXIT
START

When selecting the Diagnosis function,

communication with the ABS control is
established.
A
ECU type:
ABS/ATC-C2
WABCO Part No.:
446 004 039 4
S
Prod. date: week / year
Software No.: 3
CONTINUE

3 measured values
1 voltages
2 wheel speeds
3 switch positions
4 ECU parameters
1 display parameters (PIN)
2 change parameters (PIN)
3 print parameters (PIN)
2 System Check
(functional test)
(print results)
3 Error acc. to J1587
4 Multimeter
1 direct voltage (DC)
2 alternating voltage (AC)
3 resistance
5 Options
1 online help
2 versions
6 Special functions

The WABCO data of the ABS ECU is

displayed.
1 Error memory
3 Measured values
2 Component actuate 4 ECU parameters
Select function

EXIT

START

In the Diagnosis mode, the following

functions are available for selection:
1.1 Error memory
1.2 Component actuate
1.3 Measured values
1.4 ECU parameters
1.1

Error memory

If the ABS control unit has recognized a fault

in the system (safety lamp on), this function
helps locate the fault (example see Page
11). Depending on the type of ABS system
used and the type of error encountered, the
following advice will appear on the display.

cause and location in plain writing, e.g.

sensor error wheel A (steering axle S2),
short circuit or broken wire.
frequency at which the fault occurred.
Note:
The ECU can recognize the
error only once each time the ignition is
switched on.
error exists at present means that when
the diagnosis mode was selected the error
existed. This is followed by a detailed fault
location routine with specific instructions
on how to proceed in locating the error. If
error does not exist at present appears on
the display, this means that the fault did not
exist at the time the diagnostic mode was
selected, i.e. it cannot be located by way of
electrical measurement.
Integrated multimeter function. The tester
is instructed to carry out electrical
measurements (e.g. resistance measurements) with the aid of the measuring
adapter (ref. page 4). Both prescribed and
actual values appear on the display and
can be compared.

1.2.3

Third brake

The relay of the third brake (e.g. retarder)

can be actuated at the push of a button
(possible to hear the click sound of the relay
on some installations).
1.2.4

Different valves

The differential brake valves of the ATC

system can be individually actuated at the
push of a button. By pressing the respective
button, the valve is actuated briefly. If the
button remains pushed, the valve is
continuously actuated with short cycles.
1.2.5

ATC engine control

With this function, the electronic or pneumatic

ASR engine control fitted in the vehicle can be
actuated. Select the system fitted.
[Link] Electronic engine interfaces:

J1922 data link

When correction of the fault is confirmed,

that fault is deleted from the ECU.

Test: start engine, increase engine speed

and hold constant. Using the push-button,
reduce engine speed, then increase to original level. When test is active an increase of
engine torque should not be possible.

The fault location routine can be left only

when all faults have been corrected.

[Link] Pneumatic engine interfaces

1.2

MOT Valve on/off characteristic

(black / white)

PROP Valve proportional characteristic

Component Actuate

With Component Actuate, certain components within the ABS system can be actuated
and tested. For this the respective components must, of course, have been fitted.
1.2.1

Test: start engine, increase engine speed and

hold constant. Reduce speed via push-button
ON. After releasing the button, engine speed
is returned to its original level.

Warning lamp

The ABS warning lamp can be switched on

or off at the push of a button.

1.2.6

ABS modulator valves

[Link] Pulse programme

1.2.2

ATC lamp

The ATC lamp can be switched on or off at

the push of a button.

Both function and allocation of the ABS

modulator valves can be individually checked
by means of a pulse programme.
7

[Link] Time settings

1.3.3

The times for pressure build-up and

pressure reduction are adjustable. For
vehicles with large brake chambers, it may
be of assistance to increase pulse times to
ensure that sufficient (visible) pressurization
and venting takes place. The value is preset
at 51 milliseconds.

The positions of the ABS and ATC switches

and the status of the ATC lamp are
displayed.

1.3

Measured values

This part of the programme is used to display

values and switch positions.
1.3.1

Wheel speeds

The speeds of the ABS-controlled wheels

are displayed. As soon as the wheel speed is
more than 1.8 km/h, it will appear on the
display.

Controller data

The following system-specific ECU parameters are displayed:

WABCO ECU data

ABS configuration

ECU parameters
limiting speed: preset top speed
MIR definition: ABS bias factor on
steering axle

Voltages

The actual voltages measured by the ECU

are displayed. The valve relay voltages are
slightly below the supply voltage.
1.3.2

1.4

Switch positions

2.

SYSTEM CHECK

System check permits a complete ABS test

including print-out of a test log (e.g. after
initially fitting the system, or after extensive
repairs).
System check is divided into 2 sections:

functional test

When the wheel is stationary, the display will

show < 1.8 km/h.

print results

Note:
The diagnosis will be interrupted if all wheels
are driven. When ATC-controlled wheels are
turned at speeds in excess of approx. 3.5
km/h, ATC function is initiated, pressure is
applied to the brakes on that wheel.

Important notes: Once a test section has

been initiated, this has to be processed step
by step. It is not possible to return to, or skip,
individual steps.

If the supply voltage to the Diagnostic

Controller is interrupted, all data measured
and stored for the print log up to that point in
time are destroyed. Thus it is important that
the supply to the Diagnostic Controller is not
interrupted if a print log is required.

Functional Testing

Printer

Controller

This test is carried out with the ECU

connected. The Controller instructs the ECU
to follow certain control instructions. The
tester is confronted with individual yes/no
inquiries.
Procedure:

actuate
warning lamp
ATC lamp
third brake
ABS/ATC switch

pulse programme
This will not work on most SAE
installationes.
actuate

diff. valves of ATC-controlled driving

wheels

Speed:
Data bits:
Stop bit:
Parity bit:

1200 baud
8
1
X ON/X OFF

actuate
pneumatic engine control (PROP- or
MOT-valve) or alternatively electronical
interface

3.

ERROR ACC. TO J1587

Print System Check

At the end of the test, the results can be
printed.
As mentioned above, the Controller has to
be connected to the voltage supply at all
times. Any interruption will destroy all data
stored.
Connection with the printer is established via
the 25-pin socket on the rear and a serial
printer cable. The cable must have a DB 25plug (not socketl) at both ends.
The programme works with EPSON FXcompatible printers with a serial interface
(RS 232). The transmission parameters of
the printer must be set to the configuration
shown below:

4.

MULTIMETER

The integrated multimeter function permits

electrical measurements on the vehicle. Only
the desired measuring function (direct

Range
DC-voltage
2.0 volts
20.0 volts
50.0 volts

Display resolution

AC-voltage
2.0 volts
35.0 volts
Resistance
20.0
200.0
2.0K
20.0K
95.0K

voltage, alternating voltage or resistance)

needs to be selected. The measuring range is
automatically set by the unit.

Accuracy of measuring range. Final Value at 20C

0.1 volt
0.1 volt
0.1 volt

0.2 %
0.2 %
0.2 %

0.01 volt
0.1 volt

0.6 %
0.6 %

0.02 volt
0.4 volt

0.1
0.1
1.0
10.0
100.0

0.1
0.1
1.0
10.0
100.0

0.3 %
0.2 %
0.2 %
0.1 %
0.2 %

0.0 volt
0.1 volt
0.1 volt

Application:
direct voltage: supply voltage on vehicle
alternating voltage: sensor voltage
resistance: valves, relays, sensors, wiring

NOTE: The measuring instrument is

designed only for the vehicle range (low
voltage). It must not be used outside the
above measuring range.

5.

5.2

5.1

OPTIONS
Online Help

This function enables the user to obtain

additional information on the programme.
When the function is switched on, more detailed information will appear in suitable
places. When the card is used for the first
time, the function will be switched on.
10

Versions

This function will show the initial values of

the test facilities:

Controller hardware

Controller operating
creation date

Multimeter

Programme card with software creation

date and check total

system

with

6.

SPECIAL FUNCTIONS

After inserting the P.I.N. qualified user can

change the parameters.

EXAMPLE FOR LOCATING THE

FAULT SENSOR CABLE BREAK
The ABS control unit has
stored 1 error(s) in the error memory.
CONTINUE

Displays number of errors found.

Sensor error Wheel A (Steering S2)
(Short circuit or broken wire)
Error occurred 1x NEXT

REPAIR

Display of location of fault (sensor wheel A,

steering axle diagonal 2) and type of error
encountered (parted or broken cable). The
display also shows if the fault still existed at
the time the diagnosis was initiated. Every
time the ignition is switched on, the value is
incremented by one. Start fault locating
procedure by pressing REPAIR or display
any other faults by pressing the CONTINUE
button.
Check sensor Wheel A (Steering S2),
connecting cable and connector
for damage
Fault found
NO
YES

Visual check of the components for damage.

If no errors found, continue to Step No. 4 by
pressing NO.
Switch ignition off!
THEN disconnect measuring pin adapter,
connect ABS control unit and switch
ignition on again. CONTINUE

NOTE: When using the inter-adapter, switch

off ignition only using read toggle switch.
4-channel: measurementadapter 35 pins,
6-channel: measurementadapter 54 pins
Check resistance:
PIN 15 / 32
SHOULD BE: 0.73.0 k ACTUAL: 0.02 k
Check acutal value!
LOW CORRECT HIGH

Connect multimeter cable (red and black) to

the multimeter sockets on the Controller. Push
measuring pins into sockets 15 and 32 on the
measurement adapter. Compare actual value
measured with desired value. Using the
respective button, indicate whether the actual
reading is LOW, CORRECT (within the
tolerance range) or HIGH (in this case: reading
is LOW compared with desired value).
Disconnect sensor from connecting cable!
Check resistance: PIN 15 / 32
SHOULD BE: > 45 k ACTUAL: 0.02 k
Actual value O.K.? NO
YES

To narrow down the fault, separate the sensor

from the extension cable and again indicate
whether reading is LOW, HIGH or CORRECT
(in this case: reading is LOW again).

11

Sensor connecting cable

Wheel A (Steering S2) faulty.
Exchange faulty cable.
CONTINUE

Sensor connecting cable was isolated as the

defective part.
No FURTHER errors stored in the
ABS control unit.
CONTINUE

No FURTHER errors have been stored.

Switch ignition off!
THEN disconnect ABS control unit,
connect measuring adapter and switch
ignition on again. CONTINUE

Proceed as described in Step No. 4 but in

reverse sequence.

12

All RECTIFIED errors

are cleared in the ABS control unit!
CONTINUE

Switch ignition off and on again!

CONTINUE

After switching the ignition off and then on, the

ECU will check the wiring once again. When
using the inter-adapter the ignition must be
switched off using the red toggle switch.
No FURTHER errors stored in the
ABS control unit.
CONTINUE

Error memory was read again. The display

shows that no errors are stored in the ECU. If
this is not the case, the fault locating procedure
will commence again. To leave the fault
locating procedure, press CONTINUE.

FUNCTIONAL FAULT IN DIAGNOSTIC SYSTEM

no display

Cause

Remedy

no voltage supply
undervoltage (less than about 7 volts)

a) SAE diagnostic plug:

Check plug allocation
Voltage between PIN1 and PIN2 =
supply voltage on vehicle
b) Inter-adapter:
Switch on ignition at adapter
Check all plug-in connections

IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII

black bars

Cause

Remedy

programme card not inserted

Insert programme card, pushing it fully

home

***

Initialisation error ***

Switch ignition on!
Check diagnostic connection!
CONTINUE

Cause

Remedy

insufficient supply voltage (only during

diagnosis)

Check condition of battery and ensure

sufficient supply

13

***

LOW VOLTAGE

***
CONTINUE

Cause

Remedy

insufficient supply voltage (< 10.8 volts)

no supply voltage (ignition off)
no ECU or wrong ECU connected
Diagnostic lines switched or disconnected

Ensure supply
Switch on ignition
Check ECU and connection
Check lines and connections for function
and proper allocation

*** Wrong key word ***

Diagnosis impossible!
CONTINUE

Cause

Remedy

wrong ECU connected

wrong WABCO Data in ECU or
defective ECU

Check ECU part number

Change ECU and check ECU part
number

Defective Programme Card !

CONTINUE

Cause

Remedy

defective programme card

wrong programme card

Change programme card

14

***

COMMUNICATION
BREAKDOWN ***
Restart diagnosis procedure!
CONTINUE

Cause

Remedy

Data transmission aborted during diagnosis

Line or voltage disconnection during
diagnosis

Check all connections

a) SAE socket on vehicle:
switch on ignition
b) inter-adapter:
move red toggle
switch to 1 position

***

Unknown control unit ***

Diagnosis not possible
with this program card!
CONTINUE

Cause

Remedy

ECU cannot be tested with this

programme card

Use right programme card

*** Error during self-test ***

EEPROM of Dignostic Controller faulty

Cause

Remedy

EEPROM (Diagnostic Controller's nonvolatile memory defective

Repair Diagnostic Controller

15

!--------------------------------------------------------------------------------------------------------------------!
!
SYSTEM CHECK PROTOCOL
!
!
Motor vehicle ABS/ATC-C (SAE)
!
!--------------------------------------------------------------------------------------------------------------------!
!
!
!
......................
.........................
!
!
Vehicle No.
ECU No.
!
!===================================================================!
!
Component test
!
!--------------------------------------------------------------------------------------------------------------------!
!Component
Should be
Actual
Unit
Value
!
!--------------------------------------------------------------------------------------------------------------------!
!ECU power-supply voltage
10.8- 16.0
______
volts
______ !
!ABS-relay 1 and SILA-relay
13 - 54
______
volts
______ !
!ABS-relay 2
25 - 108
______
ohms
______ !
![Link]-relay
25 - 108
______
ohms
______ !
! INLET valve
Wheel A (S2)
4.3 - 6.1
______
ohms
______ !
!OUTLET valve
Wheel A (S2)
4.3 - 6.1
______
ohms
______ !
! INLET valve
Wheel B (S1)
4.3 - 6.1
______
ohms
______ !
!OUTLET valve
Wheel B (S1)
4.3 - 6.1
______
ohms
______ !
! INLET valve
Wheel C (D1)
4.3 - 6.1
______
ohms
______ !
!OUTLET valve
Wheel C (D1)
4.3 - 6.1
______
ohms
______ !
! INLET valve
Wheel D (D2)
4.3 - 6.1
______
ohms
______ !
!OUTLET valve
Wheel D (D2)
4.3 - 6.1
______
ohms
______ !
!Sensor resistance
Wheel A (S2)
1.4 - 2.0
______
kohms
______ !
!Sensor to ground
Wheel A (S2)
> 45
______
kohms
______ !
!Sensor voltage
Wheel A (S2)
> 0.10
______
volts
______ !
!Sensor resistance
Wheel B (S1)
1.4 - 2.0
______
kohms
______ !
!Sensor to ground
Wheel B (S1)
> 45
______
kohms
______ !
!Sensor voltage
Wheel B (S1)
> 0.10
______
volts
______ !
!Sensor resistance
Wheel C (D1)
1.4 - 2.0
______
kohms
______ !
!Sensor to ground
Wheel C (D1)
> 45
______
kohms
______ !
!Sensor voltage
Wheel C (D1)
> 0.10
______
volts
______ !
!Sensor resistance
Wheel D (D2)
1.4 - 2.0
______
kohms
______ !
!Sensor to ground
Wheel D (D2)
> 45
______
kohms
______ !
!Sensor voltage
Wheel D (D2)
> 0.10
______
volts
______ !
!DIFF valve
Wheel C (D1)
7.7 -11.3
______
ohms
______ !
!DIFF valve
Wheel D (D2)
7.7 -11.3
______
ohms
______ !
!PROP/MOT valve
15.2-22.6
______
ohms
______ !
!===================================================================!
!
Function test
!
!--------------------------------------------------------------------------------------------------------------------!
!No errors stored in the electronic control unit (ECU)
!
!ABS warning light
______
!
!ATC light
______
!
!ABS offroad switch
______
!
!ATC function switch
______
!
!Modulator
Wheel A (S2)
______
!
!Modulator
Wheel B (S1)
______
!
!Modulator
Wheel C (D1)
______
!
!Modulator
Wheel D (D2)
______
!
!DIFF valve
Wheel C (D1)
______
!
!DIFF valve
Wheel D (D2)
______
!
!PROP/MOT Engine control
______
!
!===================================================================!
!
!
!
!
!
...............
...............
...............
!
!
Place
Date
Sign
!
!--------------------------------------------------------------------------------------------------------------------!
16

17

18